Blew a plug out today
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Lead Driver
Joined: Mar 2004
Posts: 5,372
Likes: 108
From: Northern Indiana
Blew a plug out today
My wife started the truck then called me at work and told me it sounded like my old lawn boy 2 stroke lawn mower. Spit the driverside first plug out. Took the threads with it. Gonna have to call around and see what's gonna be the best bet, having the dealer fix it or ordering the time sert kit and doing it my self. Not real happy right now. Truck is a 98 EB with the 5.4.
Senior User
Joined: Aug 2011
Posts: 254
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From: Michigan
save yourself some time goto advanced auto and get a thread rapair kit for it. It is a selfthreading insert that you just put in place of the spit plug and it comes with a long sparkplug and a short boot to replace the long boot on your coilpack. I just did this on my 99 expy with the 5.4 but i spit the #4 plug in the rear on the passenger side man was it tricky to get my hands back in there. But that route of repair works great. Only problem is that kit is 68 bucks but it about the cheapest and by far easiest way to repair it. it only takes about 10 minutes well if you can get your hands in there. And after you get the insert in make sure you blow some compressed air in the cylinder just to get and shavings out before you throw the new plug in.
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Lead Driver
Joined: Mar 2004
Posts: 5,372
Likes: 108
From: Northern Indiana
Documented problem with the fords. Do a search on here and will find plenty of info on it. Only three threads holding the plugs and it just isn't enough for the compression and blows the plug out normally taking the threads with it. I know over and under tightening the spark plugsgoes along with it happening.
I will look into the advanced kit. Thx for the heads up.
I will look into the advanced kit. Thx for the heads up.
Thread Starter
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Lead Driver
Joined: Mar 2004
Posts: 5,372
Likes: 108
From: Northern Indiana
save yourself some time goto advanced auto and get a thread rapair kit for it. It is a selfthreading insert that you just put in place of the spit plug and it comes with a long sparkplug and a short boot to replace the long boot on your coilpack. I just did this on my 99 expy with the 5.4 but i spit the #4 plug in the rear on the passenger side man was it tricky to get my hands back in there. But that route of repair works great. Only problem is that kit is 68 bucks but it about the cheapest and by far easiest way to repair it. it only takes about 10 minutes well if you can get your hands in there. And after you get the insert in make sure you blow some compressed air in the cylinder just to get and shavings out before you throw the new plug in.
Looked at the Dorman kit from Advance Auto. Correct me if I am wrong but you have to have good threads to replace with this kit correct? I see some of the threads down in the whole but not much. Figured they are jacked. I thought drilling and doing an insert was the only way if the threads are damaged.
Postmaster
Joined: Jan 2009
Posts: 4,584
Likes: 3
From: Chesapeake, Va.
I used a kit that I got from the CarQuest parts store. It's made by Helicoil and is also available from Sears for about $40.00, I paid $49.00 for mine. It worked fine for me and I have had no problems ever since. I did call Helicoil to find out what to use as a bonding agent/sealer on the threads and was about to use a well known thread lock product and they told me that the best stuff to use was Ultra Gray Permetex Sealant. I followed their instruction and all is well, so far. 
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Senior User
Joined: Jan 2007
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I used a kit that I got from the CarQuest parts store. It's made by Helicoil and is also available from Sears for about $40.00, I paid $49.00 for mine. It worked fine for me and I have had no problems ever since. I did call Helicoil to find out what to use as a bonding agent/sealer on the threads and was about to use a well known thread lock product and they told me that the best stuff to use was Ultra Gray Permetex Sealant. I followed their instruction and all is well, so far.
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Postmaster
Joined: Jan 2009
Posts: 4,584
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From: Chesapeake, Va.
So did I, but I guess I'm just lucky that way. It sure was a surprize when it happened. With the plug rattling around in the valve cover it sounded just like a rod knock and then my son touched the cover and got a very high voltage wake up call.
New User
Joined: Dec 2012
Posts: 8
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The 5.4L is the VERY COMMON motor that does this. I have never seen a 4.6L do it, BUT then again the 4.6L is well known to blow the right side "head gasket", due to not having any openness between the engine and the inner fender, and all the other stuff in that corner.
I know a lot of guys with the Expedition/F-150's with the 5.4L that have had the plugs spit out of the cylinder. (most have been the #8 though)
I know a lot of guys with the Expedition/F-150's with the 5.4L that have had the plugs spit out of the cylinder. (most have been the #8 though)
Moderator
Joined: Dec 2005
Posts: 2,813
Likes: 147
From: Billings, Montana
I blew a plug out on my old 99 expy 5.4, had the threaded insert done at a local shop who was very familiar with the issue, then that blew out. Ended up having to get a whole new head.
That was the only moment that Ford really disappointed me.
That was the only moment that Ford really disappointed me.
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